Clamshell blister packaging

ABSTRACT

A packaging apparatus for packaging OTC drugs, prescription medications (e.g., “starter packs” given to patients by their physicians), or any other suitable object or substance (e.g., tablets, button cell batteries or other small parts or components) is provided. The packaging apparatus combines two thermoforming packaging techniques: clam shell packaging and blister packaging into a single package.

CROSS-REFERENCE TO RELATED APPLICATION

This claims priority to U.S. Provisional Patent Application No. 60/809,090, filed May 26, 2006, which is hereby incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to packaging and, more specifically, to clamshell packaging with an integrated blister pack.

BACKGROUND OF THE INVENTION

A typical apparatus for packaging over-the-counter (“OTC”) drugs (e.g., flu or allergy tablets) includes a conventional blister pack for enclosing the drugs and a paper carton for housing the blister pack: This configuration has several drawbacks. For example, often times the blister pack and the paper carton become separated and one or the other lost since the items are entirely separate pieces. Thus, the important drug labeling and warnings that are often printed on the paper carton may not be seen by a person who takes the OTC drugs. Also, the party who has the paper carton may find that the blister pack is missing when that party needs the medication. Further, many times a retailer must return the product to the supplier because the paper carton has worn over time. Paper cartons are also typically bulky and therefore require significant real estate in retail establishments.

In view of the foregoing, it would be desirable to provide an improved apparatus and method for packaging OTC drugs, medications or any other suitable object or substance to overcome the above stated drawbacks. The present invention minimizes, and in some aspects eliminates, the above-mentioned failures, and other problems, by utilizing the methods and structural features described herein.

Features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by the practice of the invention without undue experimentation. Features and advantages of the invention may be realized and obtained via the instruments and combinations particularly pointed out in the drawings, subsequent detailed description and appended claims.

SUMMARY OF THE INVENTION

The above and other objects and advantages of the present invention are provided in accordance with the principles of the present invention described herein. Embodiments of the present invention relate to a packaging apparatus for packaging OTC drugs, prescription medications (e.g., “starter packs” given to patients by their physicians), or any other suitable object or substance (e.g., tablets, button cell batteries or other small parts or components).

In an embodiment of the present invention, a packaging apparatus is provided. The packaging apparatus includes a first element hingedly connected to a second element. The second element has at least one cavity for an object and the first element is selectively matable with the second element. The hinge may enable movement of the first element relative to the second element such that the packaging apparatus may be positioned in an open position or a closed position. The packaging apparatus also includes a membrane fixed to the second element for sealing the cavity. The membrane is capable of being ruptured which permits passage of an object through the membrane when force is applied against the membrane by the object.

In an embodiment, the packaging apparatus also includes an additional membrane fixed to the second element to form a second barrier sealing the cavity within the second element.

Other objectives and advantages of the present invention will become apparent to the reader and it is intended that these objectives and advantages are within the scope of the present invention.

To accomplish the above and related objectives, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, reference is made to the following description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:

FIG. 1 is an above perspective of a packaging apparatus in accordance with the present invention in a closed position.

FIG. 2 is an above perspective of the packaging apparatus of FIG. 1 in an open position.

FIG. 3 is an angled-side perspective of the packaging apparatus of FIG. 1 in an open position.

FIG. 4 is an angled-above perspective of a packaging apparatus in accordance with the present invention in an open position.

FIG. 5 is a side-peripheral view of a packaging apparatus in accordance with the present invention in an open position.

FIG. 6 is a side-peripheral view of a packaging apparatus in accordance with the present invention in a closed position.

FIG. 7 is an above perspective of a packaging apparatus in accordance with the present invention in an open position.

DETAILED DESCRIPTION OF THE INVENTION

The foregoing and other features, aspects, and advantages of the present invention will be more apparent from the following detailed description, which illustrates exemplary embodiments of the present invention.

It is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways where particular configurations, process steps, and materials disclosed herein as such configurations, process steps, and materials may vary somewhat. In addition, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting. Furthermore, as will be apparent to those skilled in the art, the present invention may be embodied in other specific forms without departing from the essential characteristics thereof.

For purposes of the description of the drawings and the embodiments of the present invention, as mentioned for each drawing, each figure may not be drawn to scale. Some areas may be drawn bigger and/or simpler in order to clearly portray the improvement to what has already been established. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the invention as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention claimed. It is also to be understood that the terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting since the scope of the present invention will be limited only by the appended claims and equivalents thereof.

In an embodiment, the package combines two thermoforming packaging techniques: clam shell packaging and blister packaging to make possible the “Clamshell-Blister Pack” shown in FIGS. 1-7. Generally, a clamshell package includes a rigid thermoformed plastic container that features a hinged lid with, for example, a positive snap closure so the package can be opened and resealed. The lid may be printed with, for example, the product name and/or instructions for use. Alternatively or additionally, an insert card may be included within the clamshell package to explain the uses and features of the product. A blister package includes one or more cavities preformed in a material (typically plastic), where the material is backed by another material (e.g., paper or metal foil) to keep the product within the cavity.

FIG. 1 is an above perspective of a packaging apparatus 100 in a closed position displaying the hinged lid 102, also referred to as the top or first element, of the packaging apparatus 100. The packaging apparatus 100, also referred to as a clamshell package, includes a rigid thermoformed plastic container featuring the hinged lid 102. Those skilled in the art will recognize that the packaging apparatus 100 could be formed of a semi-rigid material, or possibly a flexible material, and still fit within the scope of the present invention. The hinged lid 102 may entail a positive snap closure so the clamshell package 100 can be opened and resealed. The lid 102 which has an interior may be printed with, for example, the product name and/or instructions for use, as described below. The printed material may be on the inside, outside or both of the lid 102. Alternatively or additionally, an insert card, sticker or other appended label (not shown) may be included within the clamshell package 100 to explain the uses and features of the product.

FIG. 2 is an above perspective of the packaging apparatus 100 in an open position. The hinged lid 102 of FIG. 1 is fixed upon a base 106 by a hinge 104. The base 106, also referred to as the second element, includes at least one cavity 114(n) for receiving an object (e.g., flu or allergy tablets or gelcaps). Those skilled in the art will recognize that the cavity 114(n) may be configured to accommodate multiple objects and typically it will include multiple cavities 114(1−n). The packaging apparatus 100 also includes a membrane 108 fixed to the base 106 for maintaining the object in the at least one cavity 114(n). The membrane 108 may seal all of the cavities 114(1−n), only some of the cavities 114(1−n) or only one of the cavities 114(1−n). The membrane 108 is capable of being ruptured and thus permitting passage of an object through the membrane 108 upon an application of force against the membrane 108. It may also be possible to rupture the membrane 108 via force applied to the base 106, which applies force to the object within the cavity, which in turn applies force to the membrane 108, thus rupturing the membrane 108 and permitting passage of the object through the membrane 108. The lid 102 and base 106 may be formed in a single and continuous form, fill, and seal process from two or more flexible films. Alternatively, other methods for forming the packaging apparatus 100 may be employed. Those skilled in the art will recognize that any combination of the lid 102 and base 106 affixed to one-another via a hinge 104 may be utilized (e.g., the lid 102, base 106 and hinge 104 as separate parts; the hinge 104 formed integral with only the lid 102 or only the base 106). Further, while the hinge has been illustrated as a single hinge running along the full length of the clamshell package 100, those skilled in the art will recognize that one or more smaller hinges could be employed without departing from the scope of the invention.

The Clamshell-Blister Pack 100 may be formed in a single and continuous form, fill, and seal process. A clear thermoplastic film such as polyvinyl chloride or a polyolefin may be printed with trademarks, labeling requirements and graphic design and then thermoformed to provide in a single piece:

1. a lid (cover) 102;

2. a base 106 containing at least one cavity 114(n) and having shoulders 110 to receive the lid 102; and

3. a living hinge 104 connecting the base 106 to the lid 102.

A second film or membrane 108 such as paper, metal foil, a laminate of paper and/or metal foil having a surface coated with a film of a thermoplastic material such as polyethylene, polystyrene, or the like, is sealed to the base 106 to seal the blister cavities 114(1−n). This process may be achieved through the conventional application of heat and pressure or in any other suitable fashion. The blister package portion 114 may contain products 115(1−n) within the blister cavities 114(1−n). These products 115(1−n) may be identical, different, grouped etc.

The base 106 may be covered by a third film 116 which also may be a rupturable membrane made of paper, foil, or a laminate of paper and foil. The third film 116 may be sealed to the bottom of the base 106 to act as a second barrier between the real world and the product 115(1−n). The third film 116 may also extend beyond the perimeter of the packaging apparatus and be used as a hang tag so the packaging apparatus 100 may be hung in a hanging display rather than stored on a shelf.

FIG. 3 is an angled-side perspective of a packaging apparatus 100 as described above in relation to FIG. 2.

FIG. 4 is an angled-above perspective of a packaging apparatus 100 as described above in relation to FIG. 2.

FIGS. 5-7 are perspective views of a packaging apparatus in accordance with embodiments of the present invention. FIG. 5 is a side-peripheral view of the packaging apparatus 100 in an open position as described above in relation to FIG. 2. FIG. 5 shows the location of the third film 116. FIG. 6 is a side-peripheral view of the packaging apparatus 100 in a closed position as described in relation to FIG. 1, in which the lid 102 and base 106 are illustrated. FIG. 7 is an above perspective of the packaging apparatus 100 in an open position, as described in FIG. 2.

INDUSTRIAL EMBODIMENTS

Illustrative advantages of the Clamshell Blister Pack will now be described. Economical: The Clamshell Blister Pack eliminates the need for, and the expense of the printed paper carton required for a conventional blister pack. It also eliminates the complex and highly regulated inventory requirements for the printed paper carton. With a conventional blister package, the blister is one component of the package and the printed paper carton is the second component. In contrast, the Clamshell Blister Pack forms the blister pack within its own integral “carton”, as stated above in reference to FIG. 2. The blister package 114 is formed within the cavity 114(n) of the base 106 of the clamshell apparatus 100. An assortment of configurations may occur between the cavity 114(n) and the blister package 114, which could include, among others, that the cavity 114(n) may be separated into multiple blister packages 114 for different products 115(1−n).

Safe: The Clamshell Blister Pack provides a tamper evident package that may permanently maintain the integrity of important drug labeling and warnings (as compared with typical paper cartons that are discarded or deteriorate).

Efficient: The Clamshell Blister Pack can be manufactured by a fully automated form, fill, and seal operation that produces a completed FDA-compliant package ready for use.

Convenient: The Clamshell Blister Pack has an extremely thin profile (up to 80% thinner than conventional packages) that allows patients to easily slip the package into a pocket to carry with them.

Patient Compliance: Each blister cavity of the Clamshell Blister Pack may be labeled or numbered to enable the patient to know if they have taken, or need to take their medication.

Maintains Quality Appearance: The Clamshell Blister Pack will not easily scuff, smear, crush, rip, or stain. It preserves a clean quality product appearance at retail and significantly reduces returns for shopworn merchandise.

Better Merchandising: The Clamshell Blister Pack is up to 80% thinner than conventional packages permitting many more packages per facing at retail and more efficient use of space for retail displays.

Space Saving and Elegant Package for Physicians' Samples: The Clamshell Blister Pack provides the perfect format for physicians' samples or “patient starter packs”.

Other features and advantages of embodiments of the present invention will be apparent from the drawings and claims.

Thus it is seen that a clamshell package with integrated blister pack and method of its manufacture are provided. Although particular embodiments have been disclosed herein in detail, this has been done by way of example for purposes of illustration only, and is not intended to be limiting with respect to the scope of the appended claims, which follow. It is contemplated by the inventor that various substitutions, alterations, and modifications may be made without departing from the spirit and scope of the invention as defined by the claims. Other aspects, advantages, and modifications are considered to be within the scope of the following claims. The claims presented are representative of the inventions disclosed herein. Other, unclaimed inventions are also contemplated. The inventor reserves the right to pursue such inventions in later claims. 

1. A packaging apparatus comprising: a first element fixed to a second element by a hinge, wherein said second element has at least one cavity configured to receive an object; said first element is configured to be selectively matable with said second element; said hinge configured to enable movement of said first element relative to said second element such that said packaging apparatus includes an open position and a closed position; and a membrane fixed to said second element of said packaging apparatus for sealing said at least one cavity, wherein said membrane is capable of being ruptured and permitting passage of an object through said membrane.
 2. The packaging apparatus according to claim 1 wherein said first element, said second element, and said hinge are formed from a single continuous piece of material.
 3. The packaging apparatus according to claim 2 wherein said material is a thermoplastic material.
 4. The packaging apparatus according to claim 1 further comprising: another membrane fixed to the second element to form a second barrier sealing the at least one cavity within the second element.
 5. The packaging apparatus according to claim 1 wherein said membrane and said another membrane are paper.
 6. The packaging apparatus according to claim 1 wherein said membrane is foil and said another membrane is paper.
 7. The packaging apparatus according to claim 1 wherein said membrane and said another membrane are foil.
 8. The packaging apparatus according to claim 1 wherein said membrane is paper and said another membrane is foil.
 9. The packaging apparatus according to claim 4 wherein said at least one cavity is formed in said second element in a manner which places said at least one cavity within an interior of said first element when said packaging apparatus is in said closed position.
 10. The packaging apparatus according to claim 1 wherein said at least one cavity is a plurality of cavities.
 11. The packaging apparatus according to claim 10 wherein said membrane covers at least one cavity of said plurality of cavities.
 12. The packaging apparatus according to claim 11 wherein said membrane covers all of said plurality of cavities.
 13. A method of manufacturing a package comprising: forming a housing that comprises an element fixed to another element by a hinge, wherein said another element has at least one cavity configured to receive an object; placing an object in said cavity; fixing a membrane to said another element of said housing proximal said object for maintaining said object in said cavity, wherein said membrane is capable of being ruptured and permitting passage of said object through said membrane upon an application of force against said membrane by said object; and fixing another membrane to said another element distal from said object relative to said membrane.
 14. The method according to claim 13 further comprising: forming the element, the another element and the hinge from a single continuous piece of material.
 15. A packaging apparatus comprising: a single piece of material formed into a lid fixed to a body by a hinge, wherein said body has at least one cavity configured to receive an object; said hinge is configured to enable movement of said first element relative to said second element such that said packaging apparatus includes an open position and a closed position; a membrane fixed to said body proximal said cavity for closing said cavity; and another membrane fixed to the second element distal from said cavity relative to said membrane. 